Abstract: Ductile iron samples alloyed with 2.5% Si, 0.78% Cu, 0.421% Mo and 0.151% Ni were austempered at 345 °C and 380 °C for 150 and 180 mins and then tested for wear strength. Ductile iron was also included in the study for comparison purposes. A pin-on-disc machine was employed for wear study. The investigations were carried out for a speed of 3 m/s, under the contact load of 29.43 N with varying sliding distances ranging from 1000 m to 5000 m. The experimental outcome indicates that ADI austempered at 345 °C is more wear resistant than the one austempered at 380 °C. Also for only a sliding distance of 3000 m, both exhibited almost same wear resistance. SEM analysis indicates running sliding marks more or less parallel to one another. Spalled layers and large voids which resemble delamination were observed on worn surface of ADI380. This indicated the occurrence of severe wear. Dark patches observed indicate oxidized surface.
Abstract: Ni alloys have managed to cover wide range of applications such as automotive industries, oil gas industries, and aerospace industries. However, these alloys impose challenges while using conventional machining technologies. On the other hand, Micro-Electro-Discharge machining (micro-EDM) is a non-conventional machining method that uses controlled sparks energy to remove material irrespective of the materials hardness. There has been always a huge interest from the industries for developing optimum methodology and parameters in order to enhance the productivity of micro-EDM in terms of reducing machining time and tool wear for different alloys. Therefore, the aims of this study are to investigate the effects of the micro-EDM process parameters, in order to find their optimal values. The input process parameters include voltage, capacitance, and electrode rotational speed, whereas the output parameters considered are machining time, entrance diameter of hole, overcut, tool wear, and crater size. The surface morphology and element characterization are also investigated with the use of SEM and EDX analysis. The experimental result indicates the reduction of machining time with the increment of discharge energy. Discharge energy also contributes to the enlargement of entrance diameter as well as overcut. In addition, tool wears show reduction with the increase of discharge energy. Moreover, crater size is found to be increased in size along with the increment of discharge energy.
Abstract: In recent years, the use of the aluminum based alloys
in the industry and technology are increasing. Alloying elements in
aluminum have further been improving the strength and stiffness
properties that provide superior compared to other metals. In this
study, investigation of physical properties (microstructure,
microhardness, tensile strength, electrical conductivity and thermal
properties) in the Al-12.6wt.%Si-%2wt.Ni ternary alloy were
investigated. Al-Si-Ni alloy was prepared in vacuum atmosphere. The
samples were directionally solidified upwards with different growth
rate V (8.3−165.45 μm/s) at constant temperature gradient G (7.73
K/mm). The flake spacings (λ), microhardness (HV), ultimate tensile
strength (σ), electrical resistivity (ρ) and thermal properties (H, Cp,
Tm) of the samples were measured. Influence of the growth rate and
spacings on microhardness, ultimate tensile strength and electrical
resistivity were investigated and relationships between them were
obtained. According to results, λ values decrease with increasing V,
but HV, σ and ρ values increase with increasing V. Variations of
electrical resistivity (ρ) of solidified samples were also measured.
The enthalpy of fusion (H) and specific heat (Cp) for the alloy was
also determined by differential scanning calorimeter (DSC) from
heating trace during the transformation from liquid to solid. The
results in this work were compared with the previous similar
experimental results.
Abstract: Sol-enhanced Zn-Ni-Al2O3 nanocomposite coatings
were electroplated on mild steel by our newly developed solenhanced
electroplating method. In this method, transparent Al2O3 sol
was added into the acidic Zn-Ni bath to produced Zn-Ni-Al2O3nanocomposite
coatings. The chemical composition, microstructure and
mechanical properties of the composite and alloy coatings deposited
at two different agitation speed were investigated. The structure of all
coatings was single γ-Ni5Zn21 phase. The composite coatings possess
refined crystals with higher microhardness compared to Zn-Ni alloy
coatings. The wear resistance of Zn-Ni coatings was improved
significantly by incorporation of alumina nano particles into the
coatings. Higher agitation speed provided more uniform coatings
with smaller grain sized and slightly higher microhardness.
Considering composite coatings, high agitation speeds may facilitate
co-deposition of alumina in the coatings.
Abstract: Al-Si-Mg-Ni(-Cu) alloys are widely used in the automotive industry. They have the advantage of low weight associated with low coefficient of thermal expansion and excellent mechanical properties – mainly at high temperatures. The corrosion resistance of these alloys in coastal area, particularly sea water, however is not yet known. In this investigation, electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization have been used to evaluate the corrosion resistance of Al-6Si-0.5Mg-2Ni (-2Cu) alloys in simulated sea water environments. The potentiodynamic polarization curves reveal that 2 wt% Cu content alloy (Alloy-2) is more prone to corrosion than the Cu free alloy (Alloy-1). But the EIS test results showed that corrosion resistance or charge transfer resistance (Rct) increases with the addition of Cu. Due to addition of Cu and thermal treatment, the magnitude of open circuit potential (OCP), corrosion potential (Ecorr) and pitting corrosion potential (Epit) of Al-6Si-0.5Mg-2Ni alloy in NaCl solution were shifted to the more noble direction.
Abstract: Effect of 2wt% Cu addition on tensile properties and
fracture behavior of Al-6Si-0.5Mg-2Ni alloy at various strain rates
were studied. The solution treated Al-6Si-0.5Mg-2Ni (-2Cu) alloys,
were aged isochronally for 1 hour at temperatures up to 300oC. The
uniaxial tension test was carried out at strain rate ranging from 10-4s-1
to 10-2s-1 in order to investigate the strain rate dependence of tensile
properties. Tensile strengths were found to increase with ageing
temperature and the maximum being attained ageing for 1 hr at
225oC (peak aged condition). Addition of 2wt% Cu resulted in an
increase in tensile properties at all strain rates. Evaluation of tensile
properties at three different strain rates (10-4, 10-3 and 10-2 s-1)
showed that strain rates affected the tensile properties significantly.
At higher strain rates the strength was better but ductility was poor.
Microstructures of broken specimens showed that both the void
coalescence and the interface debonding affect the fracture behavior
of the alloys
Abstract: Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of pulse TIG welded 70/30 Cu-Ni alloy. In order to evaluate the effect of process parameters such as pulse frequency, peak current, base current and welding speed on tensile strength of Pulsed current TIG welded 70/30 Cu-Ni alloy of 5 mm thickness, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined at 95% confidence level. The results indicate that the Pulse frequency, peak current, welding speed and base current are the significant parameters in deciding the tensile strength of the joint. The predicted optimal values of tensile strength of Pulsed current Gas tungsten arc welding (PC GTAW) of 70/30 Cu-Ni alloy welds are 368.8MPa.